Faculty Publications
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Item Development of nano-structured cyclic multilayer Zn-Ni alloy coatings using triangular current pulses(2011) Bhat, R.S.; Hegde, A.C.Cyclic multilayer alloy (CMA) deposits of Zn-Ni were developed on mild steel from sulphate bath having thiamine hydrochloride (THC) and citric acid (CA) as additives. CMA coatings were developed galvanostatically using triangular current pulses, under different conditions of cyclic cathode current density (CCCD's) and number of layers. The corrosion behaviors of the coatings were evaluated by potentiodynamic polarization and electrochemical impedance spectroscopy methods, and were compared with that of monolayer Zn-Ni alloy of same thickness. At optimal configuration, CMA coating represented as, (Zn-Ni)2.0/5.0/300 was found to exhibit ?40 times better corrosion resistance compared to monolayer alloy, (Zn-Ni)3.0. Cyclic voltammetry study demonstrated that THC and CA have improved the appearance of the deposit by complexation with metal ions. The corrosion protection efficacy of CMA coatings was attributed to the difference in phase structure of the alloy in successive layers, evidenced by XRD analysis. The formation of multilayer and corrosion mechanism was analyzed by Scanning Electron Microscopy (SEM) study. © 2011 Allerton Press, Inc.Item Corrosion stability of electrodeposited cyclic multilayer Zn-Ni alloy coatings(2011) Bhat, R.S.; Udupa, K.R.; Hegde, A.C.This paper reports on a study of electrodeposition and characterisation of cyclic multilayer coatings of Zn-Ni alloy from a sulphate bath. Cyclic multilayer alloy coatings were deposited on mild steel through the single bath technique by appropriate manipulation of cathode current densities. The thickness and composition of the individual layers of the CMA deposits were altered precisely and conveniently by cyclic modulation of the cathode current during electrodeposition. Multilayer deposits with sharp change in composition were developed using square current pulses, using thiamine hydrochloride and citric acid as additives. Laminar deposits with different configurations were produced and their corrosion behaviours were studied by AC and DC methods in 5%NaCl solution. It was observed that the corrosion resistance of the CMA coating increased progressively with the number of layers (up to certain optimal numbers) and then decreased. The decrease in corrosion resistance at high degree of layering was attributed to interlayer diffusion due to less relaxation time for redistribution of metal ions at cathode during deposition. The coating configurations have been optimised for peak performance of the coatings against corrosion. It was found that CMA coating developed at cyclic cathode current densities of 3.0/5.0 A dm-2 with 300 layers showed the lowest corrosion rate (0.112×10-2 mm/year) which is ?54 times better than that of monolithic Zn-Ni alloy, deposited from the same bath. The protection efficacy of CMA coatings is attributed to the difference in phase structure of the alloys in successive layers, deposited at different current densities, evidenced by X-ray diffraction analysis. The formation of multilayers and corrosion mechanism were examined by scanning electron microscopy. © 2011 Institute of Metal Finishing.Item Optimization of bright Zn-Co-Ni alloy coatings and its characterization(2013) Bhat, R.S.; Hegde, A.C.Acidic sulphate bath having ZnSO4.7H2O, CoSO4.7H2O, NiSO4.7H2O and thiamine hydrochloride (THC) and citric acid (CA) in combination, was optimized for deposition of bright Zn-Co-Ni alloy coating on mild steel. Bath constituents and operating parameters were optimized by Hull cell method, for highest performance of the coating against corrosion. The effect of current density (c.d.), on deposit characters, such as corrosion resistance and hardness, thickness were studied and discussed. Potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) methods were used to assess the corrosion behaviors. The composition of deposits were determined by spectrophotometeric method and confirmed by EDX analysis. Surface morphology of the deposits was examined using scanning electron microscopy (SEM). The Zn-Co-Ni alloy, with intense peaks corresponding to Zn (100) and Zn (101) and Zn (110) phases, showed highest corrosion resistance, evidenced by X-ray diffraction (XRD) study. A new and cheap sulphate bath, for bright Zn-Co-Ni alloy coating on mild steel has been proposed, and results are discussed. © 2013 by CEE.Item Production of layer by layer Zn-Fe compositional multilayer alloy coatings using triangular current pulses for better corrosion protection(Maney Publishing, 2015) Bhat, R.S.; Hegde, A.Multiple-layer coatings of Zn-Fe alloy having alternatively the same compositions have been developed galvanostatically on mild steel (MS) from a single plating bath using triangular current pulses. Thiamine hydrochloride (THC) and citric acid (CA) were used as additives. Multiple-layer coatings were developed under different conditions of cyclic cathode current density (CCCD) and number of layers. Cyclic voltammetry demonstrated that the addition of THC and CA improves the deposit character by increasing the Ni content (through suppressing the deposition of Zn) via preferential adsorption on the cathode surface. The corrosion behaviours of the coatings were evaluated by electrochemical AC and DC methods. The optimum multiple-layer coating, represented as (Zn-Fe)3.0/5.0/300, was found to exhibit about four to five times better corrosion resistance when compared with monolayer (Zn-Fe)3.0 alloy, developed from the same bath for the same duration. Distinct phase structures responsible for interface formation between successive layers (which changes alternatively) were confirmed by X-ray diffraction analysis. Better corrosion resistance afforded by multiple-layer coating was attributed to the increased specific surface area of the coating because of layering. A synergistic effect of both structural difference between layers and individual layer thickness is responsible for enhanced corrosion resistance of the multiple-layer coatings. The formation of multiple layers and corrosion mechanism were analysed by scanning electron microscopy. © 2015 Institute of Materials Finishing.Item Electrochemical studies on the corrosion resistance of Zn–Ni–Co coating from acid chloride bath(Springer, 2020) Bhat, R.S.; Manjunatha, K.B.; Prasanna Shankara, R.; Venkatakrishna, K.; Hegde, A.C.Anticorrosive deposits are a valuable approach to defending against corrosion from mild steel structures/machinery equipment. The Zn–Ni–Co coating has been deposited on low carbon steel surfaces using environment friendly optimized acidic chloride bath with ZnCl2·6H2O, NiCl2·6H2O, CoCl2·6H2O, sulphanilic acid (C6H7NO3S) and gelatin (C6H8O6). The standard Hull cell technique has been adopted for the optimization of bath components and experimental conditions, for the superior corrosion resistant coating. The corrosion test with potentiodynamic polarization method was performed to investigate the role of pH on the film quality and corrosion performances of the films. Further, the effect of current densities on corrosion resistance, thickness and hardness, have been investigated. Cyclic voltammetry technique has been used to test the electrochemical properties of the Zn–Ni–Co coating in acidic solutions. The results revealed that the increase in the current density favoured the increase in Ni and Co content in the deposit, showed higher corrosion resistance and higher cathodic current efficiency. The structural and morphological characteristics of the alloy coating have been obtained through scanning electron microscopy and X-ray diffraction techniques. The atomic force microscope was used to examine the topographic structure of the coating. X-ray Photoelectron spectroscopy was used to determine the chemical composition of alloy coatings and verified by energy dispersive X-ray analysis. The results indicate that a new and low-cost chloride bath for Zn–Ni–Co coating exhibit superior corrosion resistance properties and can be implement in various industrial applications such as automobiles, machine tools etc.[Figure not available: see fulltext.]. © 2020, Springer-Verlag GmbH Germany, part of Springer Nature.Item Compositionally Modulated Multilayered Zn-Co Deposits for Better Corrosion Resistance(Springer, 2020) Bhat, R.S.; Venkatakrishna, K.; Nayak, J.; Hegde, A.C.Zn-Co compositionally modulated multilayer alloy (CMMA) deposits have been developed onto mild steel using single bath technique. Multilayer alloy coatings have been galvanostatically produced using square current pulses. The switched cathode current density and number of layers have been designed for improved corrosion resistance. Experimental data revealed that multilayer coating with 120 layers at 10/30 mA/cm2 demonstrated ~ 125 times higher resistance to corrosion than monolayer alloy coating of the same thickness. The improved corrosion resistance of multilayer coatings is due to small changes in the wt.% cobalt, leading to change in the phase structure of deposit in alternate layers. The defects and failures occurring in a single layer in the deposition process are covered by the alternatively deposited coating layers. Therefore, the direction of the corrosive agent is extended or blocked. Further, the better corrosion resistances afforded by Zn-Co CMMA coatings were explained through changes in electronic properties at the interface, supported by Mott-Schottky’s plot. However, the decrease of corrosion resistance at a high degree of layering is attributed to the less relaxation time for redistribution of solutes in the diffusion layer, during plating. Potentiodynamic polarization and electrochemical impedance data showed its good protection ability. The enhanced corrosion resistance of multilayered deposits is due to small change in cobalt content, leading to alter the phase structure of the alternate-layers of the deposits. The structural morphology and the topographical structure of the coating were analyzed by scanning electron microscopy and atomic force microscopy. Evaluation of the chemical composition of the alloy coatings was carried out by x-ray photoelectron spectroscopy. © 2020, ASM International.Item Electrodeposition of Zn–Co Coating and its Electrochemical Performance(Pleiades journals, 2022) Bhat, R.S.; Manjunatha, K.B.; Venkatakrishna, K.; Hegde, A.C.Abstract: We report the acid chloride bath based electroplating of Zn–Co alloy on low carbon steel (LCS). As additives, the sulphanilic acid (SA) and gelatin were used for electroplating. The bath exhibited an anomalous co-deposition with a higher deposition of Zn over nobler Co. The role of bath composition, current density, partial current density, pH, and temperature on thickness, hardness, and corrosion resistance of deposit was studied. The corrosion behavior in 3.5 wt % sodium chloride solution and electrochemical behavior in acid chloride solutions of Zn–Co alloy coatings were studied using the potentiodynamic polarization method and cyclic voltammetry technique respectively. Mott–Schottky plot with positive slope confirms the development of n-type semiconductor layer at the interface of substrate and coating, which results in superior corrosion resistance of coatings. The colorimetric method has been used to estimate the composition of the deposit and further verified by energy dispersive X-ray spectroscopy (EDX) technique. The surface features and the topographical structure of the alloy film were obtained by scanning electron microscopy (SEM) and atomic force microscopy (AFM) techniques. The results indicate that the Zn–Co alloy films exhibited superior corrosion resistance with the lowest corrosion rate (138 µm y–1). Hence this alloy coating will find suitable applications in automobile and aerospace industries. © 2022, Pleiades Publishing, Ltd.Item Electrochemical Studies of Zn-Ni-Fe Alloy Coatings for Better Corrosion Resistance Applications(Springer, 2022) Bhat, R.S.; Munjunatha, K.B.; Bhat, S.I.; Venkatakrishna, K.; Hegde, A.C.Anti-corrosive alloy coatings are a valuable solution to the protection of low carbon steel structures/equipment against corrosion. The Zn-Ni-Fe coatings have been deposited galvanostatically on low carbon steel from an acid chloride bath. Sulfanilic acid and gelatin were used as additives for the homogeneity of the deposit. The Hull cell method has been used to optimize both bath constituents and plating conditions. The corrosion behavior of the coating films was examined with potentiodynamic polarization and the electrochemical impedance spectroscopy methods. The effects of current density, pH, and temperature on deposit properties like hardness, thickness, and corrosion rates were examined. The electrochemical characteristics of the Zn-Ni-Fe have been studied by the cyclic voltammetry technique. The morphology of the deposit was investigated with scanning electron microscopy and the surface roughness of the coating film was analyzed by atomic force microscopy. The Ni and Fe contents in the deposit were analyzed by colorimetric technique and cross-checked with energy-dispersive x-ray analysis. The capacitive reactance at the interface is attributed to the excellent corrosion resistance at optimal current density (40 mA cm−2) as indicated by the Nyquist plot with large polarization resistance. Furthermore, the positive slope of Mott-Schottky revealed that the semiconductor film at the interface is n-type. The results show that a new Zn-Ni-Fe alloy coating film exhibits better corrosion resistance properties and can be executed in industrial applications such as machine tools, bolts, and nuts in the automobile for corrosion protection, etc. © 2022, ASM International.